Hydrovane HV01-02.2013 Parts

Illustrated Parts
and Service Manual
501/502 Series
Stationary Air Compressors
ST 15926-00
GB
Issue B Mar 00
Introduction
This publication contains parts lists and service information please read it carefully before you attempt to service or carryout adjustments on
the compressor.
This service manual should be used in conjunction with the user handbook.
Note: If you need any specialist help or service, please contact your distributor or CompAir UK Hydrovane quoting the MODEL TYPE and
SERIAL NUMBER.
Product development
CompAir UK Hydrovane adopt a policy of continual product Improvement. The information in this handbook, whilst fully up to date when
issued, may be subject to change without notice.
Quality standards
CompAir UK Hydrovane Quality Management Systems are approved to BS EN / ISO 9002.
CompAir UK Hydrovane Limited
Claybrook Drive
Washford Industrial Estate
Redditch
Worcestershire
B98 ODS
England.
E-mail:
Telephone:
Fax:
Sales@Hydrovane.co.uk
Redditch
(01527) 525522
Rediditch
(01527) 521140
(AN INVENSYS COMPANY)
Model range
This handbook relates to all 01/02 50 Hz compressors, model types:
501-009570-9903 onwards
502-010828-9902 onwards
Classic 01
Classic 02
PURS10
PURS10
PRDS10
PRDS10
PUTS10
PUTS10
Terminology:01 & 02
1.1 & 2.2 kW
10
Normal working pressure (bar)
PURS
Package Unit, Receiver and Starter
PUTS
Package Unit, Tripod and Starter
PRDS
Package Unit, Receiver, Dryer and Starter
01/02 Classic
Parts/Service Manual
English
ST 15926-00
Iss B 03/00
CompAir Ltd
Introduction
OWNERSHIP RECORDS
Model Number:
.................................
Serial Number:
.............................
R.P.M:
.................................
Kw:
.............................
Maximum Bar:
.................................
Local CompAir UK Distributor

Name:
.................................
Contact:
.............................
Address:
.................................
Telephone:
.............................
.................................
Fax:
.............................
.................................
Email:
.............................
GENERAL HEALTH AND SAFETY PRECAUTIONS

Please read carefully and proceed in accordance with the following instructions before installation,
operation, maintenance or repair of the compressor unit.
The Health and Safety at Work Act, 1974
In order to comply with your responsibilities under the above act, it is
essential that the compressor is transported, positioned, installed,
operated and maintained by competent persons in accordance with
the instructions in this handbook.
The compressor warranty will be invalidated if unapproved spare parts
or lubricants are used. Using such items may cause the efficiency and
service life of the compressor to be reduced and could create a
hazardous condition over which CompAir UK Hydrovane has no
control.
Failure to maintain the compressor correctly, or modifying it without
prior approval from CompAir UK Hydrovane, may also create a
hazardous condition. This will also invalidate the warranty.
Consequential damage of any nature is not covered by the warranty.
Read and fully understand the contents contained in the user
handbook.
Ensure that the user Handbook is not permanently removed from the
compressor.
Check that there are no signs of damage and/or oil leaks from the
air-end, cooler and associated pipework.
After completing work, tools and foreign matter should be removed
from the compressor and its surrounding area.
In the unlikely event of a compressor fire, dry powder or carbon dioxide
fire extinguishers should be used. Never use water.
Before Working on Compressor

1. Potentially dangerous voltages are used to power this
machine. Do not carry out any work until the isolator is locked in
the off position. Fit a safety notice to the isolator advising that
work is being carried out and that the isolator must not be
switched on. If in doubt then a qualified electrician may remove
the fuses and keep them in a secure place until work is
complete.
2. Ensure the compressor has been safely isolated from the
main air system and cannot be re-introduced until all work has
been completed. Fit a safety notice to the isolation valve
advising that work is being carried out.
3. Do not undertake any work until the compressor and
receiver if fitted, have been relieved of all pressure.
4.
Wait until the compressors vent down cycle is complete.
5. Open the test valve to release any pressure contained in

the aftercooler or associated pipework.
6. Check that the air-end pressure gauge reads zero. Do not
proceed until it does.
7. Carefully unscrew the compressor filler plug. If any air or oil
escapes before plug is fully removed stop! Do not remove the
plug until all pressure is lost.
8. Safety devices fitted to the compressor or air-line system
should be checked at regular intervals and replaced if faulty.
They should not be tampered with or modified. Non return valves
should not be used as isolation devices.
9. To ensure the compressor operates safely you must carry
out the specified maintenance procedures.
10. Only approved lubricants should be used for flushing
purposes.
11. Extreme caution should be taken if the compressor has
been subjected to severe operating temperatures or fire. Certain
components may contain fluoroelastomer materials and under
these conditions can leave extremely corrosive residues.
Severe burns and permanent skin and tissue damage can be a
result of skin contact.
12. The Health and Safety information contained in this
Handbook is only intended to give general guidelines.
Page 1
Introduction
GENERAL HEALTH AND SAFETY PRECAUTIONS
(continued)
When Operating the Compressor
7. Eye Contact - *Mildly irritating. Flush with copious amounts of

warm water. Seek medical advice if necessary.
1. When in automatic mode the compressor will re-start without

warning.
8. Aspiration - If there is any suspicion of aspiration into the

lungs (for example during vomiting) admit to hospital immediately.
2. If an automatic re-start device is fitted (allowing the

compressor to start when power is re-applied), or operation is
controlled from a remote location, additional warnings will be
required.
9. Inhalation - Remove from exposure into fresh air. If necessary

give artificial respiration or oxygen. Seek medical advice.
3. Do not remove any plugs or release pipework when the

compressor is running.
4. Do not attempt to open the starter enclosure while the
compressor is operating.
5. Beware of hot surfaces, both the air-end and electric motor are
designed to run at elevated temperatures.
6. Compressed air is potentially dangerous and can be fatal if
misused. Do not allow compressed air jets, discharged from any
pipe or nozzle, to make contact with your body.
7. Wear safety glasses and suitable clothing when using, or
working in an area where compressed air is being used.
8. Hazardous vapours/fumes can be produced if compressed air
is used to remove chemicals, cleaning agents and lubricants from
equipment and components. Suitable respiratory and extraction
equipment may be required in these circumstances. Never use
compressed air for cleaning personal clothing.
9. Do not use air directly from compressors for breathing
purposes. If the air is to be used for human consumption then it
must be subjected to further treatment to ensure that the levels of
contaminants, odour and moisture meet the requirements of
BS 4275 1974
10. We recommend that the air supply to hand held air guns is
regulated to a lower pressure (refer to local Health and Safety
regulations).
11. Do not insert any object or part of body through any opening of
the compressor enclosure. Serious personal injury and/or damage
may result.
12. Never run the compressor when any covers or guards are
missing, unless advised to do so in this handbook.
10. Pressure injection - Obtain immediate medical attention,

even if injury appears minor.
* See Cautionary Notice SHW 397 Effects of Mineral Oil on the
Skinand MS(B) 5 Skin Cancer Caused by Oilpublished by the
Health and Safety Executive.
11. Spillage - Soak up with absorbent clay.
12. Waste Disposal - Oil, condensate, filter elements etc. should
be disposed of in accordance with local regulations. Do not allow oil
to contaminate water supplies.
Warnings, Cautions and Notes

1.
Warning
WARNING is used in the text of this handbook to identify specific

hazards which can cause injury or death. This type of hazard is
identified below.
Risk of electric shock
Risk of danger
Risk of hot surfaces
Pressurised vessel
Pressurised ocmponent or system
Unit is remotely controlled and may
start without warning
Potential Oil Health Hazards
Eye Protection Must be worn
This section relates to Fluid Force oil. For other lubricants

refer to the Health and Safety Instructions issued with the
relevant product.
Dust protection must be worn
1. There are no significant hazards associated with this product

when properly used and in the application for which it was
designed. Frequent and/or prolonged skin contact may give rise to
skin irritations and it is recommended that protective gloves are
worn. The carcinogenic action of mineral oils should be brought to
the attention of all users. *
Read the instruction manual
2.
2.
The oil may be hot so take care when carrying out oil changes.
3. Do not keep oily rags in pockets or wear contaminated

clothing. Do not inhale fumes or vapours. Do not swallow. Avoid eye
contact.
4. Always wash hands after use and before eating, drinking,
smoking and using the toilet.
5. Ingestion - Do not induce vomiting because of the risk of
aspiration. Wash mouth out with water. Give 1/2 pint milk. Seek
immediate medical attention.
6. Skin Contact - *Mildly irritating. Remove by wiping. Wash with
soap and water. Apply emollient cream.
Do not operate the machine without

the guard being fitted.
Caution
CAUTION is used in the text of this handbook to identify incorrect

procedures which can cause damage to the compressor.
3.
Notes
NOTE is used in the text of this handbook to draw attention to

specific points of importance.
Hydrovane declines all liability in the event of material damage or
bodily injury resulting from negligence in the application of these
precautions, from non-observation or lack of elementary
supervision in respect of handling, operation, servicing or repair,
even if not expressly stated in this instruction notice.
Page 2
CompAir Ltd
Introduction
Servicing requirements
Note: The following preventive maintenance charts cover all Hydrovane compressors using Hydrovane Fluid Force oils. The work to be
carried out must be done on or before the hours shown for this action.
Read health and safety precautions before starting any work.
Service schedule: Fluid Force Clear Oil (1000 Hour oil change)
The bulk oil temperature must not exceed 90c. If the oil is working above this temperature, the oil life will be reduced.
Note: When changing to Fluid Force Clear the compressor must be flushed out with Fluid Force Prime in order to comply with USDA H1
standard.
Preventative Maintenance Schedule

Maintenance Actions and Manual
Reference
Fluid Force Clear

Install
Every Every Every Every Every

Every Every
1000 2000 6000 12000 24000
Day Week
hrs
hrs
hrs
hrs
hrs
Suitable sited
Adequate ventilation
Ambient temperature
Sufficient access
Clear of airborne contaminants
Torque electrical connections
Check oil level at filler plug
1B
Check correct drive rotation
Check for air leaks
5I
Check for oil leaks
5J
Check air filter
1C
Check power on load
Check power off load
Check oil temperature
1B
Check motor cable glands secure
Check motor for damage
Check motor cables and earth
Check motor for vibration
Check motor for loose connections
1C
Check oil seal

Check drive media
Check operation of non-return valve
Check starter contactors
Check motor insulation resistance

Clean air/oil radiator external
1C
Clean external dirt from motor
1C
Clean external dirt from compressor
1C
Page 3
Introduction
Reference
Fluid Force Clear

Install
Clean air filter
2A
Change MPV seals
1D
Change separator element
1C
Change Fluid Force Clear oil
1C
Change air filter
1C
Change intake valve seals

Every Every
1000 2000 6000 12000 24000
Day Week
hrs
hrs
hrs
hrs
hrs
Change thermal motor (501 PURS)

Change drive media
2C
Change oil return filter

Change oil seal
1F
Change pressure gauge

Test minimum pressure valve
5E
Test air delivery
5C
Page 4
CompAir Ltd
Introduction
Service schedule: Fluid Force 2000 (2000 Hour oil change)
The bulk oil temperature must not exceed 90c (Fluid Force 2000) or 100c (Fluid Force HPO). If the oil is working above this temperature, the
oil life will be reduced.
Note: When changing recommended oil types it is advisable to flush the compressor.

Reference
Fluid Force 2000/HPO

Install

Every Every
1000 2000 6000 12000 24000
Day Week
hrs
hrs
hrs
hrs
hrs
Suitable sited
Adequate ventilation
Ambient temperature
Sufficient access
Clear of airborne contaminants
Torque electrical connections
Check oil level at filler plug
1B
Check correct drive rotation
Check for air leaks
5I
Check for oil leaks
5J
Check air filter
1C
Check power on load
Check power off load (PUTS)
Check oil temperature
1B
Check motor cable glands secure
Check motor for damage
Check motor cables and earth
Check motor for vibration
Check oil seal
Check drive media
Check motor for loose connections
1C
Check operation of non-return valve

Check starter contactors
Check motor insulation resistance

Clean air/oil radiator external
1C
Clean external dirt from motor
1C
Clean external dirt from compressor
1C
Clean air filter
Change Fluid Force 2000 oil
1C
Change air filter
1C
Page 5
Introduction
Reference
Fluid Force 2000/HPO

Install

Every Every
1000 2000 6000 12000 24000
Day Week
hrs
hrs
hrs
hrs
hrs
Change intake valve seals
2A
Change MPV seals
1D
Change separator element
1C
Change thermal motor (501 PURS)

Change drive media
2C
Change oil seal
1F
Change pressure gauge

Test minimum pressure valve
5E
Test air delivery
5C
Page 6
CompAir Ltd
Introduction
Service Kits
Only use genuine CompAir UK Hydrovane parts and approved oils. Oils must not be mixed.
Service kits contents

Item
Part Number
Quantity
Description
Chapter Location
KM51 - Maintenance Kit

1
74015
Air filter
2A
57029
9609
Separator element
2A
Bonded Seal
9611
Bonded Seal
9613
Bonded Seal
9615
Bonded Seal
2B
9703
O Ring
2A
9709
O Ring
2A
9711
O Ring
2A
10
9821
O Ring
2A
2B
KT52 - Top Up Kit

1
71553
Oil seal
2B
56391
Gauge
2A
74014A
Shim, Red
2B
74014B
Shim, Blue
2B
74014C
Shim, Green
2B
73101
Gasket, Separator End Cover
2A
58365-01
Gasket (cork)
2B
71550
Gasket (rubber)
2B
9707
10
O Ring
2B
10
9718
O Ring
2A
11
32653
Oil return plug assembly
2A
12
56300
O Ring
2B
13
56410
Flexible pipe
14
56422
Valve seat
15
56423
Coupling element (white)
16
56528
Insert
2B
17
56565
Coupling element (black)
2D
18
56624
Fibre washer
2A
19
58327
Copper washer
2A
20
70952
Coupling element (blue)
21
9754
O ring
22
9648
Copper Washer
23
58117
Lens
24
58426
Lens clip
2A
2C, 2D
Note: Spare parts to be stored in original packaging and in a dry environment. Repaired or replacement units should be protected against
corrosion and mechanical damage during storage.
Page 7
Introduction
Key to symbols used
20
20
Nm
Nm
Torque Setting Nm.
22mm
Spanner Required (mm) A/F
Silco
660
Grease Required (Specification)
6mm
Allen key Required (mm)
577
Loctite Required and Specification Number
S
105
S
105
Service Tools Required and Part Reference

Lubricate With Sump Oil
Recommended Oils
Recommended Grease
Fluid Force Clear
Silkolene 660
Fluid Force 2000
Motor Grease
Esso Unirex N3
Shell Albida R2
Note: Do not mix oils.
Shell Nerita HV
SKF LGHQ3
Castrol Optimol PD2
Torque settings
Listed below are recommended torque settings.
Note: Torque settings must be applied when indicated.
Torque Settings
Thread Size (mm)
Setting (Nm)
15
35
10
60
12
95
16
160
42
400
Page 8
CompAir Ltd
Introduction
Service Tools required
1.5 Wide undercut to base

of thread
36.0
Nozzle orifice
Dia A (mm)
Dia 'A' Ream

Tol :- 0.025
12.0
18.5
13.7
3/8 BSP
3/8 BSP
120
60
Model
Bar
C.F.M
1.00
01
10
23.6
1.98
02
10
31.5
9.0
12.0
Material EN1A
Service Tools (Test Nozzle)
1mm
1mm wide
wide xx 2mm
2mm
deep
deep
10.00
200.00
6mm Dia
Dia bar
bar
6.00
Material
Material mild
mild steel
steel bar.
bar.
Stator Slave Stud (S73)
Page 9
Introduction
120
165
127
Material
Material
Mild
Mild Steel
Steel
Two Leg Puller (S34)
15
18
15
Stator
110
65
50
18
Sep
3.0
40
Setting Gauge (S89)
Page 10
CompAir Ltd
Introduction
This page is intentionally left blank
Page 11
Parts List and Service Manual

Contents
Chapter
Page
Routine Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 14
Air-end. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . 20
Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . 40
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . 48
Adjustments and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . 52
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . 56
Page 12
CompAir Ltd
Page 13
Routine Servicing
Chapter 1
Contents
Section
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A . . . . . . . 15
Checking Operation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B . . . . . . . 15
Check the Compressor Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check Pressure - Air-line System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check Pressure - Compressor Air-end. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Draining Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Basic Service Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C . . . . . . . 15
Oil Top Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Check Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressor Air Intake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Clean Cooler and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Minimum Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D . . . . . . . 18
Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E . . . . . . . 18
Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F . . . . . . . 18
Page 14
CompAir Ltd
Routine Servicing
A Introduction
Check oil level
WARNING !
Check that the air-end pressure gauge reads zero.
Remove filler plug and check inside oil chamber.
Oil should be filled to overflow if not top up (see oil top-up

procedure).
READ HEALTH AND SAFETY PRECAUTIONS

BEFORE YOU START ANY SERVICE WORK.
Ensure genuine parts are available for fitment.
Draining air receiver (see fig 1.1)
Frequency of service work will depend on:a)
Time periods mentioned in introduction.
Wait for air-end vent down cycle to finish.
b)
Climatic conditions.
Position suitable container beneath condensate drain valve (E).
c)
Installation.
WARNING !
B - Checking Operation of the Compressor

Check the compressor operating temperature
Wait until air-end vent down cycle is complete.

Pour a small amount of oil into the thermometer pocket of the oil filler
plug. Screw a temperature gauge or thermometer into the
thermometer pocket.
Assuming the compressor is serviced correctly the machine is
capable of operating in ambient temperatures up to a maximum of
40oC. At this ambient the bulk oil temperature measured at the filler
plug should be 70-90oC.
Check oil temperature. When the compressor is working the
temperature should be:< 70oC
Initial start-up and warm-up period.

Optimum working temperature.
70 - 95oC
High temperature.
95 -100oC
>100oC
Stop ! See fault finding section.
Check pressure - air-line systems

Check the air-line system pressure by using the receiver mounted
pressure gauge.
Condition
10 bar
When compressor is stopped
9.6 - 10.4 bar
Normal working pressure
8.0 -9.6/10.4 bar
Check pressure - compressor air-end

To check the air-end pressure, use the pressure gauge located in
the air-end.
Condition
10 bar
Pressure when stopped
After vent down air-end

pressure should read
0 bar
Initial start up (3 seconds approx.)
0 - 4.0/6.0 bar
When charging the air-line
4.0/6.0 - 9.6/10.4 bar
Normal working pressure
8.0 - 9.6/10.4 bar
When compressor is stopped
9.6/10.4 - 0 bar
Page 15
THE AIR RECEIVER IS PRESSURISED, TAKE

GREAT CARE WHEN CARRYING OUT THE NEXT
OPERATION. DO NOT ALLOW ANY COMPRESSED
AIR JETS TO MAKE CONTACT WITH YOUR BODY.
Carefully open drain valve (E) and allow pressure to fall slowly to
zero. Collect all condensate drained from receiver.
Note: Condensate may contain traces of oil and must be disposed

of in an approved manner.
Close drain valve (E) and open air outlet valve (A).
C - Basic Service Procedures

WARNING !
STOP THE COMPRESSOR AND ISOLATE FROM
MAINS ELECTRICAL SUPPLY. LOCK THE
ISOLATOR IN THE OFF POSITION. FIT A SAFETY
NOTICE TO THE ISOLATOR ADVISING THAT
WO R K I S B EI N G C A R R I ED O U T O N T HE
COMPRESSOR.
CLOSE THE AIR OUTLET VALVE TO ISOLATE THE
COMPRESSOR FROM THE AIR-LINE SYSTEM. FIT
A SAFETY NOTICE TO THE VALVE ADVISING
THAT IT IS NOT TO BE OPENED.
DO NOT PROCEED UNTIL GAUGE READS ZERO!
WHEN CHANGING RECOMMENDED OIL TYPES IT
IS ADVISABLE TO FLUSH THE COMPRESSOR.
WHEN CHANGING TO FLUID FORCE CLEAR THE
COMPRESSOR MUST BE FLUSHED OUT WITH
FLUID FORCE PRIME.
Routine Servicing
Oil Top-up procedure (Fig 1.1)
Wait until the air-end vent down cycle is complete.
Note: If pressure gauge does not fall to zero then non-return

valve (D) may be faulty.
Drain air receiver following procedure above. Do not reopen

air-outlet valve (A).
Carefully unscrew oil filler plug (B).
Remove filler plug (B), retain bonded seal (C).
Fill to overflow with an approved oil (e.g. Fluid Force) Do not

overfill
B,C
D
A
Note: Oils must not be mixed
Examine bonded seal, if not damaged refit to filler plug.
Refit seal and filler plug, tighten to 25 Nm.
Remove safety notices.
Figure 1.1 - Outlet and Filler Plug Location
Check compressor air filter (Fig 1.2)

WARNING !
The air filter (C) is located beneath the filter cover (A). Filter cover will
slide over adapter and pipe (B).
Wait until air-end vent down cycle is complete.
Open test valve to vent pressure from the receiver and

associated pipework.
Check that air-end pressure gauge reads zero.
Firmly pull filter cover (A) to remove from separator casing.
Remove air filter (C), slide over adaptor and pipe (B).
Clean separator casing and inside of filter cover.
Vacuum clean or blow dust out of filter using low pressure, clean
dry air. Renew filter as below if it cannot be cleaned satisfactorily.
Refit air filter (C), locate on support gauze (D).
Refit filter cover (A).
C,D
Figure 1.2 - Air filter location
Compressor air intake filter replacement (Fig 1.2)

The air filter (C) is located on support gauze (D) beneath the filter
cover (A). Disconnect pipe (B).
Firmly pull filter cover (A) to remove from separator casing.
Remove filter (C) and clean separator casing and inside of cowl.
Note: Air filter may contain traces of oil and must be disposed of in
an approved manner.
Fit a new filter (C), locate on support gauze (D).
Refit filter cover (A) and reconnect pipe (B).
Page 16
CompAir Ltd
Routine Servicing
Clean cooler and motor (Fig 1.3)

WARNING!
Carefully vacuum clean the oil cooler matrix (A), aftercooler (B) if
fitted and guard rings (C) on the lantern.
Vacuum clean or blow dust from motor (D) and motor grill, using
low pressure, clean dry air.
Remove safety notices and open air-outlet valves.
Turn mains electrical supply on. Test run compressor and check
there are no air leaks.
A B C
Figure 1.3 - Cooler and motor location

Replacing the oil separator element (Fig 1.4)
Remove cap head screws (A).
Gently tap the end cover (B) until it is clear of the separator
casing.
Unscrew the oil separator element (C) and discard.
E
C
D
Note: Oil separator element contains oil and must be disposed of

in an approved manner.
Fit a new separator element. Ensure that the O ring (E) is in

place. Do not over tighten.
Refit end cover (B). Ensure cover is positioned correctly and bolt
holes are in line. Be careful not to damage O ring (D) when
refitting.
Refit cap head screws (A). Tighten to 6 Nm.
B
A
Figure 1.4 - Separator element location

Oil change procedure (Fig 1.5)
Remove filler plug (A), discard bonded seal (B).
Place container, at least 1.0 Litre capacity, beneath oil drain

plug (D).
Carefully remove drain plug (D) and discard bonded seal (C).
Collect all the oil that drains from the compressor.
Note: Any waste oil collected must be disposed of in an approved

manner.
Refit drain plug (D) using a new bonded seal. Tighten to 20 Nm.
Fill to overflow with an approved oil (e.g. Fluid Force). Do not

overfill.
Note: Oils must not be mixed
Refit filler plug (A) using a new bonded seal. Tighten to 25 Nm.
Turn mains electrical supply on and open air-outlet valve.
Test run compressor. Check pressure and Inspect for oil leaks.
Figure 1.5 - Oil change procedure

Page 17
Routine Servicing
Electrical checks
Remove drive coupling.
WARNING !
Remove screws.
Remove the starter panel and pressure switch covers.
Pull oil seal assembly out of oil chamber.
Check for any signs of overheating and ensure that all electrical
connections are tightened to correct torque settings.
Clean seal housing and remove burrs on chamber (C).
Refit new seal and remove applicator.
Fit power coupling in correct position.
Renew O rings on cooler couplings.
Fit new seal using service tool S72 and secure with fixing
screws.
Reassemble compressor and fill with oil.
Note: Pay special attention to power connections and cables

connected to contactors and incoming terminals.
Refit and secure covers.
Check electric motors

WARNING !
Remove any dust or dirt from motor bodies and motor air intake
grills.
Reinstate all covers.
Remove safety notices.
D - Minimum Pressure Valve (Fig 1.6)
Remove separator end cover (A).
Remove circlip (B). Parts (C) and (D) will be pushed out by
spring (J).
Remove piston (G). This is simplified using long nose pliers.
Renew O rings (E) (F) and (H). Apply smear silicon grease
before fitting.
Check piston (G) and non return valve (D) for wear. Renew if
necessary.
Testing of the minimum pressure valve is itemised in Chapter 5.
Figure 1.6 - Minimum Pressure Valve
E - Pressure Control Valve; (PUTS only)

Oil Return Valve (Fig 1.7)
Drain oil.
Remove separator housing (A).
Remove pressure control valve (B) and note settings. (7 or

10 bar).
Renew bonded seal (C).
Remove oil return valve (D). Renew filter and O ring (E) if
unserviceable. Renew bonded seal (F).
Renew flexible tube (G).
When fitting separator housing use two studs S73 to ensure

correct alignment of tube (G) with discharge pipe on stator.
Separator feed tube (H) should be positioned 18 2 to machine

axis on assembly. Setting gauge S83 will simplify this operation.
Refill compressor with oil when assembly is complete.
Testing of the control valve is itemised in Chapter 5.
Figure 1.7 - Pressure Control Valve and

Oil Return Valve
F - Oil Seal (Fig 1.8)
Drain oil.
Before any work can be carried out on the seal the compressor
must be removed from the motor.
Remove lantern and cooler.
Figure 1.8 - Oil Seal

Page 18
CompAir Ltd
Routine Servicing
Page 19
Air-end
Chapter 2
Contents
Chapter
Page
Separator: Intake End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A . . . . . . . 21

Oil Chamber; Rotor Stator Unit; Lantern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B . . . . . . . 25
PURS: Motors; Couplings; Receivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C . . . . . . . 31
PUTS: Motors; Couplings; Tripod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D . . . . . . . 33
Aftercooler; Dryer Mk1; Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E . . . . . . . 35
Aftercooler; Dryer Mk2; Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F . . . . . . . 37
Air End Parts Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G . . . . . . . 39
Note: Parts contained in service kits are shown in kit column. Apply Loctite sparingly. Ensure cross
drillings etc. do not become blocked.
Page 20
CompAir Ltd
2A
Separator: Intake End Cover

Description
Kit
Quantity
Item
Part Number
56633
Outlet tap (PUTS models only)
57574
Intake filter cowl
32254
Separator cover assembly
56914
Separator end cover
9413
Spring
9703
O Ring
56838
MPV Piston
56836
Valve plate
9709
O Ring
KM51
9711
O Ring
KM51
10
56837
MPV end plug
11
MCI 19
Circlip
12
MS705-20
Socket head screw M5 x 20mm
13
56391
Pressure gauge
KT52
14
9821
O Ring
KM51
15
74015
Intake filter
KM51
16
70416
Intake filter support
34044
Intake end cover assembly
17
73129
Intake end cover
18
56637
Bearing
19
70392
Sleeve
20
56659
Restrictor
21
56437
Valve plate
22
56422
Intake valve seat
KM51
All
01
KT52
Refer to Health and Safety section before carrying

out any service work.
Changing air filter
Pressure control valve, oil return valve
Refer to Basic Service Procedures.
Fit parts contained in service kits.
Removing minimum pressure valve
Refer to Chapter 1-D
Changing oil separator
Remove end cover (3).
Renew O ring (14).
Unscrew oil separator (42).
Renew O ring (43).
Oil separator cannot be cleaned. If found to be faulty or blocked it

must be renewed.
Page 21
Refer to Chapter 1-E
02
2A
4
5
Silco
660
6
7
Silco
660
Silco
660
9
10
12
11
6
Nm
4mm
2
16
15
1
14
1
13
Nm
17
18
601
31
32
33
34
35
36
25
19mm
22
19
24
14mm
39
27
30
41
43
26
42
29
21
23
19
13
Nm
28
44
19mm
37 45
38 47
601
46
13
Nm
19mm
40
13
Nm
5mm
Figure 2A - Separator: Intake End Cover
Page 22
CompAir Ltd
2A

Part Number
23
9718
24
MCI-26
Circlip
25
73101
Gasket
26
56801
Lift plate
27
56426
Screw
28
57443
Pressure control valve (PUTS machines only)
29
57531
Bush (PUTS machines only)
30
56289
Safety valve (PURS machines only)
31
34078
Discharge tube assembly
32
56431
Discharge fitting
33
56434
Nut
34
56624
Fibre washer
35
32410
Oil separator feed assembly
36
MG1706-06
Grub screw
37
73100
Oil impingement cowl
38
58327
Folded copper washer
34407-03
Description
O Ring
Kit
Quantity
Item
KT52
All
1
1
KT52
KT52
KT52
Separator casing assembly
39
73034
Separator case
40
56299
Socket head screw M6 x135mm
41
56275
Separator stud
42
57029
Oil separator element
43
9799
O Ring
44
70166
Blowdown valve filter & O Ring
45
58307
Oil return plug
46
57244
Filter
47
58327
Folded copper washer
Refer to Health and Safety section before

carrying out any service work.
Intake assembly
Remove screws (27), lift plate (26) and circlip (24).
Fit parts contained in service kit.
Refill compressor with approved oil when assembly is complete.
Page 23
KM51
KT52
01
02
2A
4
5
Silco
660
6
7
Silco
660
Silco
660
9
10
12
11
6
Nm
4mm
2
16
15
1
14
1
13
Nm
17
18
601
31
32
33
34
35
36
25
19mm
22
19
24
14mm
39
27
30
41
43
26
42
29
21
23
19
13
Nm
28
44
19mm
37 45
38 47
601
46
13
Nm
19mm
40
13
Nm
5mm
Figure 2A - Separator: Intake End Cover
Page 24
CompAir Ltd
2B
Oil Chamber; Rotor Stator Unit; Lantern

Description
Kit
Quantity
Item
Part Number
1a
56281
Rotor
1b
57775
Rotor (PUTS models only)
2
3a
70233
74014C
Blade
Shim - green
3b
74014D
Shim - amber
3c
3d
74014A
74014B
Shim - red
Shim - blue
73999
Stator assembly
5
6
56302
56586
Valve plate
Valve support
2
2
AGS203-B
8
9
FS702-3
57416
10
All
01
02
1
1
KT52
8
A/R
A/R
KT52
KT52
A/R
A/R
Lockwasher
Socket head screw 4BA

Tension pin
2
2
73995
Outlet assembly
11
12
13
56300
73997
56637
O Ring
Oil chamber
Bearing
14
15
16
GHC2-6
GHC3-6
73917
17
18
19
9611
71127
9615
20
21
71553
MS1606-20
KT52
Helicoil
Helicoil
Drain plug
1
1
1
1
1
1
Bonded seal
Filler plug
Bonded seal
KM51
Oil seal
Countersunk screw
KT52
KM51
1
1
1
1
2

Blades and slots must be perfectly clean and fitted with rounded
edge outwards. Marks must be correspond with slots if original
blades are refitted.
Rotor stator - removal
Examine stator for damage. Ensure cutaway is clearly defined

by two straight lines along length of bore.
Ensure stator bore and end faces are free from debris.
Remove drive coupling (refer to 3C).
Stand oil chamber (12) verticaly on wooden blocks.
Remove intake end cover and discard gasket (refer to 2A).
Remove stator (4). Note position and thickness of shims (3).
Stand oil chamber vertically on wooden block.
Remove rotor having first removed grub screw burrs on shaft to

retain blades (2) in position.
Renew O ring (11).
Apply smear of oil to 0.0015 (0.038mm) shim and position pipe.
Discard O Ring (11).
Fit rotor complete with blades.
Rotor stator - Examine
Fit new oil seal.
Inspect both end faces and bearings for wear. Renew if

necessary.
Fit drive coupling.
Stand main casing on block of wood and apply oil to bearing.
Check overall end clearance using straight edge and feeler

gauges between rotor and stator.
Place rotor (1) in casing. Refit new oil seal. Fit drive coupling.
Apply smear of oil to end stator and fit shims to give total end
clearance of between 0.003 (0.076mm) and 0.004 (0.089mm).
If blades (2) are to be re-used they must be removed from the

slots and marked using a felt tipped pen (NOT SCRATCHED) so
that each blade can be replaced in the same position.
Fit intake end cover, using service tool S73.
Renew gasket.
Page 25
Rotor stator - Refitting
2B
22
12
S
89
577
10
23
11 7
24
6
Nm
13
21
18
45
20
26
25
3
5
19
15
25
Nm
22mm
17
2
270
38
42
41
29
31 30
27
36
16
20
Nm
28
37
33
32
39
33
34
39 31
35
29
30
40
43 44
Figure 2B - Oil Chamber; Rotor Stator Unit; Lantern
Page 26
CompAir Ltd
2B
Item
Part Number
Description
22
71550
Cooler gasket
23
9607
Bonded seal
24a
73845
24b
Kit
Quantity
01
02
Thermoswitch (PU/PURS models only)
72079-01
Thermistor probe (PUTS models only)
25
PE567-C6
Pozipan screw
26
PE553
Cable clip
27
56528
Insert (PURS models only)
28
32153
Thermostatic valve assembly (PURS models only)
29
MN110
Nut
30
MWG-10
Spring washer
31
MW10
Washer
32
MS708-30
Screw M8 x 30
33
MWG-8
Spring washer
34
MS708-25
Screw M8 x 25
35
57630
Backplate
36
56383
Guide ring
37
32446
Lantern assembly
38
57563
Guard ring
39
56393
Cooler stud
40a
57774
Lantern (PUTS models only)
40b
70485
Lantern (PURS models only)
41
58365
Cooler gasket
42a
56294
Oil cooler
42b
57773
Oil cooler (PUTS models only)
43
9707
O Ring
44
56386
Cooler coupling
45
74261
O Ring
KT52
All
1
1
KT52
1
1
KT52
1
1
1
1
KT52

Oil Cooler
Oil Relief Valve; Stator Discharge Pipe
Remove compressor from motor.
Remove screw (8) and washer (7).
Remove drive media.
Remove support (6) and valve plate (5).
Remove backplate if applicable (35/36) and lantern (37/38/40).
Check plate (5) for wear or damage. Renew if necessary.
Remove oil cooler (42).
Ensure valve seating face is perfectly flat. Use emery stone to

obtain flatness.
Remove cooler couplings (44).
Renew self adhesive gaskets (41) and (22).
Remove all traces of emery dust.
Renew O rings (43).
Renew. washer (7) and reassemble.
Discharge pipe (10) should be positioned 15 1/2 to machine

axis on assembly. Setting gauge S89 will simplify this operation.
Page 27
2B
22
12
S
89
577
10
23
11 7
24
6
Nm
13
21
18
45
20
26
25
3
5
19
15
25
Nm
22mm
17
2
270
38
42
41
29
31 30
27
36
16
20
Nm
28
37
33
32
39
33
34
39 31
35
29
30
40
43 44
Figure 2B - Oil Chamber; Rotor Stator Unit; Lantern
Page 28
CompAir Ltd
2C
PURS: Motors; Couplings; Receivers

Description
Kit
Quantity
Item
Part Number
70061
Drive key compressor
2a
70068
Coupling
2b
71909
Coupling
56955
Grub screw
4a
56565
Coupling spider
4b
70952
Coupling spider
5a
57487
Impellor/Motor coupling
5b
70950
56589
Drive key motor
7a
56441-32
Motor 1.1Kw 1 220/240v or
7b
73769-10
7c
57240
7d
73043
7e
72148-32
7f
73770-10
74016
Safety valve
56540
1/2 BSP Hex nipple
10
56633
Outlet tap
11
58664
Pressure gauge
12a
74004
Pressure switch and starter
12b
74005
Pressure switch and starter (single phase M/C)
12c
74121
Pressure switch & starter 1.1Kw 3 380/415V
12d
74423
12e
74124
12f
74122
All
01
02
1
1
1
4
1
KT52
1
1
1
1
1
1

Compressor removal / re-fitting
Removing bell housing
Disconnect the thermistor / thermoswitch probe cable from

either the pressure switch assembly (PURS) or the starter
assembly (PUTS).
Using an extension socket remove screws and washers.
Compressor drive coupling
Drain the oil from the compressor and cooler into a suitable
container.
Before dismantling the drive the compressor air end must be

removed from the motor.
Disconnect the pipework from the compressor to aftercooler,

where applicable.
Remove the drive element (4) examine for wear and replace if
necessary.
Support the compressor before removing 4 off nuts and washers

from the motor flange.
For improved access the lantern and cooler assembly can be

removed if desired.
If required remove 4 off cap head screw securing the backplate,

where fitted.
Remove the compressor coupling (2) and key (1), examine and
replace necessary.
Remove the compressor from the support and place on a

suitable work surface.
On re-assembly ensure setting dimensions on page 30 are

achieved for the coupling.
Ensure grub screw (3) have the correct torque and locktite
applied.
Page 29
2C
242
13
Nm
3
1
2b
5b
6
4b
242
13
Nm
3
1
2a
5a
6
4a
2119
18
20
12
13mm
577
15
18
16 17
17 18
20 19
11
9
20
22
23
21
24
22
23
25
22mm
577
18mm
15
14
22mm
10
14
13
Figure 2C - PURS: Motors; Couplings; Receivers
Page 30
CompAir Ltd
2C

Description
Kit
Quantity
Item
Part Number
14
58958
Male to female elbow
15
73938
Receiver 75 litre
16
33305
Pipework assembly, containing:
17
56934
Elbow
18
57690
Adaptor
19
57687
Non-return valve
20
70666
Stud coupling
21
70949
Delivery pipe
22
MS108-25
23
MW8
24
25
All
Hex head bolt M8 x 25mm
Washer M8
MWG8
Spring washer M8
MN108
Nut M8
01
02

Motor drive coupling
On-reassembly ensure setting dimensions on page 34 are

achieved for the coupling.
Before dismantling the drive the compressor air end must be

removed.
Ensure grub screws (3) have the correct torque and locktite
applied.
Remove fan coupling (5) and key (6), examine and replace if
necessary.
COMPRESSOR COUPLING
501: SETTING ACHIEVED BY TAPPING

COUPLING DOWN TO HEADED KEY
MOTOR COUPLING
X
MOTOR
501: LOCATION RING TO REAR OF IMPELLOR X = 2 MM
502 PURS: COUPLING TO SEAL FACE X = 13.5 MM
502 : LOCATION RING TO REAR OF IMPELLOR X = 5 MM
502 PUTS: COUPLING TO SEAL FACE X = 35 MM
Page 31
2C
242
13
Nm
3
1
2b
5b
6
4b
242
13
Nm
3
1
2a
5a
6
4a
2119
18
20
12
13mm
577
15
18
16 17
17 18
20 19
11
9
20
22
23
21
24
22
23
25
22mm
577
18mm
15
14
22mm
10
14
13
Figure 2C - PURS: Motors; Couplings; Receivers
Page 32
CompAir Ltd
2D
PUTS: Motors; Couplings; Tripod

Part Number
70061
Drive key compressor
2a
70068
Drive coupling
2b
71909
Drive coupling
3a
56565
Coupling spider
KT52
3b
70952
Coupling spider
KT52
56955
Grub-screw
5a
57487
5b
70950
56589
Drive key motor
7a
56441-32
Motor 1.1 Kw 1 220/240V or
7b
73769-01
Motor 1.1 Kw 3 380/415V or
7c
57240
Motor 1.5 Kw 1 220/240V or
7d
73043
Motor 1.5 Kw 3 380/415V or
7e
72148-32
Motor 2.2 Kw 1 220/240V or
7f
73770-10
Motor 2.2 Kw 3 380/415V or
MS108-25
Hex head bolt M8 x 25mm
MW8
Washer M8
10
MWG8
Spring washer M8
11
MN108
Nut M8
12
50474D
Self tapping screw
13
56758
Lock-nut
14
59800
Cable gland
Starter (refer to chapter 3)
15
Description
Kit
Quantity
Item
All
1
1
4
1
1
1
33734-01
Starter 240V 1.1 Kw
15b
33732-01
Starter 415V 1.1 Kw
15c
33736-01
Starter 220/240V 2.2 Kw
15d
33732-03
Starter 415V 2.2Kw
16
72114
Starter support plate
17
56572
Tripod
18
72112
Cable gland M16 con
Page 33
02
15a

01
PUTS: Motors; Couplings; Tripod
2b
2D
5b
3b
4
5a
2a
13
Nm
242
13
Nm
3a
242
6
4
8
7
9
10
11
12
18
13,14
15
17
16
Figure 2D - PUTS: Motors; Couplings; Tripod
Page 34
CompAir Ltd
2E
Aftercooler; Dryer Mk1; Filters

Description
Part Number
1396
Equal coupling
1397
Stud coupling
1892
Stud coupling
3534
Assembled drain filter
54474
Spire fastener
59067
Support cowl
59068
Cowl (Aftercooler)
59069
Aftercooler
70793
Hex nipple
10
56934
Bend
11
57687
Valve
12
72376
Pipe-Air end to aftercooler
13
73535
Support bracket
14
73537
Pipe dryer/Receiver
15a
73538
Dryer
15b
73539
Dryer
16a
73541
Bracket
16b
73542
Bracket
17
73554
Stud elbow
18
57690
Adaptor
19
CF0005B
Filter GP 9 L/S
19a
CE0005B
Element
20
CF0005C
Filter HE 9 L/S
20a
CE0005C
Element
21
GP1019
Kit-wedge
22
MN105
Nut M5
23
MN106
Hexagon Nut M6
24
MS106-16
Hex head screw M6 x 16mm
25
MS2105-10
Pozi panhead screw M5 x 10mm
26
MS705-45
Skt head screw M5 x 45mm
27
MW6
Plain washer M6
28
MWG5
Spring washer M5
29
MWG6
Spring washer M6

Change the filter elements (19a & 20a) every 12 months.
Page 35
Kit
Quantity
Item
All
01
02
1
1
1
1
Aftercooler; Dryer Mk1; Filters
2E
8
6
5
25
12
17
23
1
15
16
27
29
13
24
577
10
18
22
28
11
14
20, 21
4
19
26
Figure 2E - Aftercooler; Dryer; Filters - Mk 1
Page 36
CompAir Ltd
2F
Aftercooler; Dryer Mk 2; Filters

Description
Part Number
73619
Adaptor
1397
Stud coupling
1892
Stud coupling
3534
Assembled drain filter
54474
Spire fastener
59067
Support cowl
59068
Cowl (Aftercooler)
59069
Aftercooler
9a
70793
Hex nipple
9b
73619
Adaptor
10
56934
Bend
11
57687
Valve
12
72376
Pipe-Air end to aftercooler
13
74380
Support bracket
14
73537
Pipe dryer/Receiver
15a
74373
Dryer
15b
74374
Dryer
16
74381
Bracket
17a
73554
Stud elbow
17b
1884
Stud elbow
18
57690
Adaptor
19
CF0005B
Filter GP 9 L/S
19a
CE0005B
Element
20
CF0005C
Filter HE 9 L/S
20a
CE0005C
Element
21
GP1019
Fixing kit - filters
22
MN105
Nut M5
23
MN106
Hexagon Nut M6
24
MS106-16
Hex head screw M6 x 16mm
25
MS2105-10
Pozi panhead screw M5 x 10mm
26
MS705-45
Skt head screw M5 x 45mm
27
MWG5
Spring washer M5
28
MWG6
Spring washer M6

Change the filter elements (19a & 20a) every 12 months.
Page 37
Kit
Quantity
Item
All
01
02
1
1
1
1
1
1
1
Aftercooler; Dryer Mk 2; Filters
2F
6
8
7
5
25
12
28
16
17
23
15
24
13
577
10
22
27
18
11
14
20, 21
4
19
26
435A009
Figure 2F - Aftercooler; Dryer Mk 2; Filters
Page 38
CompAir Ltd
2G
Air End Parts Modifications

Air End Parts Modifications
Serial No. Prefix
Page 39
Compressor(s)
Ref.
New Part(s)
Old Part(s)
Service Bulletin
Starter Assemblies
Chapter 3
Contents
Chapter
01/02 Three phase (PUTS) starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A . . . . . .
Page
41
01 Single phase (PUTS) starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B . . . . . . . 43

02 Single phase (PUTS) starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C . . . . . . . 45
Starter assembly part modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D . . . . . . . 47
Note: For compressors with receivers (PURS) starters are a combined unit with the pressure switch see 2C.12a-f.
Page 40
CompAir Ltd
3A
01/02 Three Phase (PUTS) Starter

Quantity
Item
Part Number
Description
Kit
Starter Assembly No.

33732-01
33732-03
72105
Motor cable
50935
Warning label
57123
Mains cable
72758
Safety barrier
71895-01
Over-temperature circuit board
6a
72016
Overload 3.0/4.7 Amp
6b
72017
72014
Contactor
72034
Emergency stop push-button
72135
Start push-button (green)
Starter assembly 33732-01 = 501 (415Volt, 3 Phase, 50 Hz)

Starter assembly 33732-03= 502 (415Volt, 3 Phase, 50 Hz)

Page 41
01/02 Three Phase (PUTS) Starter
3A
Figure 3A - 01/02 Three Phase (PUTS) Starter
Page 42
CompAir Ltd
3B
01 Single Phase (PUTS) Starter

Quantity
Item
Part Number
Description
Kit

33734-01
72106
Motor cable
50935
Warning label
56627
Mains cable
72758
Safety barrier
71895-01
Over-temperature circuit board
73791
72015
Contactor
72134
72135
Starter assembly 33734-01 = 501 (220/240 Volt, Single Phase, 50 Hz)

Page 43
3B
Figure 3B - 01 Single Phase (PUTS) Starter
Page 44
CompAir Ltd
3C

Quantity
Item
Part Number
Description
Kit

33736-01
72135
72134
52014
Warning label
56677
M20 Cable gland
56758
M20 Lock-nut
58712
Mains cable
72112
M16 Cable gland
72113
M16 Lock-nut
MS2104-25
M4 x 25mm Pozi pan head screw
10
73145
Transformer 240V - 24V 24VA
11
72461
Enclosure
12
72151
Contactor
13
72152
Overload 18 - 25 Amp
14
72144
Motor cable
15
72093
Over-temperature control PCB
Starter assembly 33736-01 = 502 (220/240 Volt, Single Phase, 50 Hz)

Page 45
3C
Figure 3C - 502 Single Phase Starter
Page 46
CompAir Ltd
3D
Starter Assembly Part Modifications

Starter Assembly Parts Modifications
Serial No. Prefix
Page 47
Compressor(s)
Ref.
New Part(s)
Old Part(s)
Service Bulletin
Labels
Chapter 4
Contents
Chapter
Label Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A . . . . . .
Page
49
Label Assembly parts Modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B . . . . . . . 51
Page 48
CompAir Ltd
4A
Labels
Item
Part Number
Description
34303
Label PURS 501-504
2a
34299
Label 501
2b
34300
Label 502
34302
Label assembly - Classic 501-504

Page 49
Kit
Quantity
All
01
02
1
1
1
1
Labels
4A
Figure 4A - Labels
Page 50
CompAir Ltd
4B
Labels Parts Modifications

Label Parts Modifications
Serial No. Prefix
Page 51
Compressor(s)
Ref.
New Part(s)
Old Part(s)
Service Bulletin
Adjustments and Testing
Chapter 5
Contents
Section
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A . . . . . . . 53
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B . . . . . . . 53
Check Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C . . . . . . . 53
Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D . . . . . . . 54
Minimum Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E . . . . . . . 54
Safety Valve Lift Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . 54
Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G . . . . . . . 54
Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H . . . . . . . 55
Air Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . . . . 55
Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J . . . . . . . 55
Page 52
CompAir Ltd
A - Introduction
WARNING !
BEFORE MAKING ANY ADJUSTMENTS.
Adjustment procedures shown must only be carried out by

authorised persons fully trained and competent in the maintenance
of CompAir UK Hydrovane compressors.
B
A
If you are not able to carry out the work safely, contact your CompAir
UK Hydrovane distributor.
B - Pressure Switch (Fig. 5.1)

The pressure switch (C) is located in the air receiver and is pre-set at
the factory. The recommended cut-out pressure (high pressure
switch setting) is a maximum and must not be exceeded. The cut-in
pressure (re-start pressure switch setting) may be adjusted to suit
your application.
Factory setting 10 bar machines:Cut-out = 9.6-10.4 bar (max) Cut-in = 6.0 - 6.8 bar
Note: Do not adjust unless pressure switch is under pressure and
the compressor has been safely isolated from the mains electrical
supply.
Pressure sensing
Since the pressure switch is located into the air receiver we
recommend that you do not fit a non-return valve in your air-line
system.
If a non-return valve is essential for your application then the
air-supply to the switch must be relocated after the non-return valve.
C - Check Setting Procedures

Cut-out (stop) pressure:
Close air-outlet valve (A).
Start compressor, allow pressure to rise until compressor

cuts-out (stops).
Check and record cut-out pressure shown on pressure

gauge (B).
Cut-in (re-start) pressure:-
Carefully open air-outlet valve (A), allow pressure to fall slowly

until compressor cuts-in (re-starts).
Check and record cut-in pressure shown on pressure gauge (B).
Stop compressor.
Page 53
Figure 5.1 - Pressure Switch Location
D - Pressure Switch Adjustment (Fig. 5.2)
Close air-outlet valve (A).
Start compressor, allow pressure to rise until compressor

cuts-out (stops).
To adjust the cut-out higher (stop) pressure; turn the screw

marked (P1) towards:minus (-) to reduce cut-out pressure; compressor stops at
a lower pressure.
P
-
Remove pressure-switch cover.
Dp
P1
ISOLATE THE COMPRESSOR FROM MAINS

ELECTRICAL SUPPLY. LOCK THE ISOLATOR IN
THE OFF POSITION. FIT A SAFETY NOTICE TO
THE ISOLATOR ADVISING THAT WORK IS BEING
CARRIED OUT ON THE COMPRESSOR.
WARNING !
P2
Figure 5.2 - Pressure Switch Adjustment
plus (+) to increase cut-out pressure; compressor stops at

a higher pressure.
Note: Cut-out, higher (stop) pressure must not be set above
10.4 bar.
To adjust the lower cut-in (start) pressure; turn screw marked

(P2) towards:minus (-) to reduce differential and restart the compressor
at a higher pressure.
plus (+) to increase differential and restart the
compressor at a lower pressure.
Re-fit pressure-switch cover.
Switch mains electrical supply on.
Start compressor and carry-out check settings procedure.
E - Minimum Pressure Valve
(Fig. 5.3)
Close outlet valve and start compressor.
Open outlet valve fully to atmosphere.
Check the gauge pressure reading.
When set correctly the gauge should show 5 bar. The valve will
operate satisfactorily between 4 bar and 6 bar.
F - Safety Valve Lift Pressure

(Where fitted)
Figure 5.3 - Minimum Pressure Valve and Safety

Valve Lift Pressure
(Fig. 5.3)
Safety valve preset to lift as follows:

10 bar compressor = 11 bar.
Should the safety valve be faulty it cannot be adjusted and must

be renewed as a complete unit.
G - Pressure Control Valve (Fig. 5.4)
Close outlet valve and start compressor (continuous run).
Gauge should read 10.5 bar max (10 bar PUTS).
Should gauge read differently DO NOT attempt to adjust the

valve. Renew as a complete unit.
Note the pressure setting written on valve when reordering.
Figure 5.4 - Pressure Control Valve

Page 54
CompAir Ltd
H - Oil Temperature
Allow compressor to run for 30 minutes in order to attain its

normal working temperature.
Average running temperature should be

approximately 60C above ambient.
I - Air Output (Fig. 5.5)
Screw test nozzle into compressor outlet.
Close outlet valve and start compressor (continuous run).
Open outlet valve fully. Pressure on gauge should not fall below
9.5 bar (10 bar machine).
J - Leakage Check
Examine all external seals, gaskets and pipe connections for air
or oil leakage. No leaks are permissible.
Figure 5.5 - Air Output
Page 55
Fault Finding
Chapter 6
Contents
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
High Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Low Air Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Compressor Stops Unexpectedly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Page 56
CompAir Ltd
Fault Finding
Introduction
WARNING !
BEFORE YOU START ANY SERVICE WORK.
SERVICING OF THE COMPRESSOR MUST ONLY
BE CARRIED-OUT BY AUTHORISED PERSONS
FULLY TRAINED AND COMPETENT IN THE
MAINTENANCE OF COMPAIR UK HYDROVANE
COMPR E SSOR S. THEY
MUST
FUL LY
UNDERSTAND AND ADOPT CORRECT AND SAFE
WORKING PRACTICES.
If you are unable to carry-out the work safely in the required manner
then your CompAir UK Hydrovane distributor will be pleased to help.
The range of minor faults which may occur with your Hydrovane
compressor can be grouped under the following four categories:
HIGH TEMPERATURE
Pressure rises until

safety valve lifts.
HIGH PRESSURE
Oil temperature higher

than 90C.
LOW AIR OUTPUT
Lack of air at point of

usage.
EXCESSIVE OIL
CONSUMPTION
Oil discharged into air

system.
The symptoms and actions for these faults are detailed on the
following pages.
Page 57
Fault Finding
High Temperature
High temperature
Compressor
cuts out
Thermostatic valve
stuck in closed position
No
Compressor
seizing
Yes
Rectify
Incorrect stator
end clearance
No
Yes
Rectify
Reduce oil
life
Oil relief valves leaking
No
Yes
Rectify
Incorrect oil level

No
Yes
Top up
No
Unapproved oil/incorrect
grade of oil being used
No
Yes
Internal oil passage

blocked
Replace
Yes
Rectify
Oil return
plug blocked
No
Yes
Rectify
Dirty or blocked cooler

No
Yes
Clean
No
Re-circulation of hot air

or lack of ventilation
No
Yes
Internal high pressure

to low pressure leak
Yes
Rectify
Rectify
Fault
Fault
Model
type
Model type
Symptom
Symptom
Cause
Cause
Page 58
CompAir Ltd
Fault Finding
High Pressure
Fault
Fault
Model
type
Model type
Symptom
Symptom
Cause
Cause
Page 59
Fault Finding
Low Air Output
Compressor Stops Unexpectedly
Low or no air
output (cfm)
Compressor stops
unexpectedly
Malfunction of air
tools / equipment
Pressure switch
set low
No
Rapid pressure loss

in air system
Adjust
Over-temperature
fault
No
Pressure gauge
reading less than
normal
Rectify
Motor overload tripped

No
Check compressor air

output, using air-flow
indicator
Rectify
Supply voltage low

No
Rectify
Compressor seizing
If pressure display
reading normal
If pressure display
reading less than normal
Restriction in airline e.g.

Valves closed
Air intake filter blocked
No
Yes
Rectify
Minimum pressure
valve stuck closed
Yes
No
Yes
No
Rectify
Rectify
Pressure control valve

stuck in open position
Rectify
No
Yes
Rectify
Separator element
blocked
Yes
Rectify
Fault
Fault
Model
type
Model type
Symptom
Symptom
Cause
Cause
Page 60
CompAir Ltd
Fault Finding
Excessive Oil Consumption
Fault
Fault
Model
type
Model type
Symptom
Symptom
Cause
Cause
Page 61

Hydrovane HV01-02.2013 Parts

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Illustrated Parts

and Service Manual

(AN INVENSYS COMPANY)

1.1 & 2.2 kW

Normal working pressure (bar)

Package Unit, Receiver and Starter

Package Unit, Tripod and Starter

Package Unit, Receiver, Dryer and Starter

Local CompAir UK Distributor

GENERAL HEALTH AND SAFETY PRECAUTIONS

Before Working on Compressor

Wait until the compressors vent down cycle is complete.

5. Open the test valve to release any pressure contained in

7. Eye Contact - *Mildly irritating. Flush with copious amounts of

1. When in automatic mode the compressor will re-start without

8. Aspiration - If there is any suspicion of aspiration into the

2. If an automatic re-start device is fitted (allowing the

9. Inhalation - Remove from exposure into fresh air. If necessary

3. Do not remove any plugs or release pipework when the

10. Pressure injection - Obtain immediate medical attention,

Warnings, Cautions and Notes

WARNING is used in the text of this handbook to identify specific

Potential Oil Health Hazards

Eye Protection Must be worn

This section relates to Fluid Force oil. For other lubricants

Dust protection must be worn

1. There are no significant hazards associated with this product

Read the instruction manual

3. Do not keep oily rags in pockets or wear contaminated

Do not operate the machine without

CAUTION is used in the text of this handbook to identify incorrect

NOTE is used in the text of this handbook to draw attention to

Preventative Maintenance Schedule

Fluid Force Clear

Every Every Every Every Every

Clear of airborne contaminants

Torque electrical connections

Check oil level at filler plug

Check correct drive rotation

Check for air leaks

Check for oil leaks

Check air filter

Check power on load

Check power off load

Check oil temperature

Check motor cable glands secure

Check motor for damage

Check motor cables and earth

Check motor for vibration

Check motor for loose connections

Check oil seal

Check operation of non-return valve

Check starter contactors

Check motor insulation resistance

Clean external dirt from motor

Clean external dirt from compressor

Fluid Force Clear

Clean air filter

Change MPV seals

Change separator element

Change Fluid Force Clear oil

Change air filter

Change intake valve seals

Every Every Every Every Every